Battery Module Insulating Sheet Structure for Lower Height and Weight
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Solution Overview
Problem
Conventional battery modules face issues with increased height and weight due to cover plates, leading to space and performance problems when installed in vehicles, particularly affecting running performance and fuel efficiency.
Innovation Solution
A battery module design featuring an insulating sheet layer between the battery cell stack and the module frame with an opening in the upper surface, allowing for reduced height and weight while maintaining insulation and accommodating a temperature sensor, using a polycarbonate film for the insulating sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover plate is arranged on the battery cell stack to secure insulation and prevent damage, then insulation performance and protection are improved, but the height and weight of the battery module increase
Solution Approach 1:
The patent extracts the cover plate from the battery module structure and replaces it with an insulating sheet layer integrated into the module frame. This removes the harmful element (cover plate causing height increase) while preserving the useful function (insulation and protection).
Solution Approach 2:
The patent changes the material parameter from a rigid cover plate to a thin insulating sheet layer, fundamentally altering the physical parameters of the insulation component. This reduces thickness and weight while maintaining insulation performance through material properties rather than structural thickness.
2Reliability
If a cover plate is arranged on the battery cell stack to secure insulation and prevent damage, then insulation performance and protection are improved, but the weight of the battery module increases
Solution Approach 1:
The patent removes the heavy cover plate from the battery module structure and replaces it with a lightweight insulating sheet layer, directly addressing the weight problem while maintaining the essential insulation function.
Solution Approach 2:
The patent employs a thin film insulating sheet layer instead of a rigid cover plate. This thin film structure provides the necessary insulation and protection functions with minimal weight, leveraging the properties of thin film materials to achieve weight reduction.
3Reliability
If the height of the battery module is increased by adding a cover plate, then insulation and protection are improved, but more installation space is required
Solution Approach 1:
The patent extracts the cover plate that occupies valuable installation space and replaces it with a thin insulating sheet layer that integrates into the existing module frame structure, thereby reducing the overall volume while maintaining protection functions.
Solution Approach 2:
The patent transitions from a three-dimensional cover plate structure to a two-dimensional thin sheet layer, fundamentally changing the dimensional characteristics of the protection component. This reduces the height dimension while maintaining the protective function through the sheet layer's material properties.
Data Source
AI summary
A battery module includes a battery cell stack formed by stacking a plurality of battery cells, a module frame for housing the battery cell stack, and an insulating sheet layer located between the battery cell stack and the upper surface of the module frame, wherein an opening is formed in the upper surface of the module frame, and a protrusion inserted into the opening is formed in the insulating sheet layer.